Photovoltaic (PV) products are manufactured in many countries and sold all over the world. Most work well and are very reliable, with the result that industry market growth is higher now than at any time in the last 15 years. From available worldwide statistics, it appears that product failures are rather few but they are still significant. In addition, the module performances produced by some manufacturers does not always meet customer expectations.
Even though the overwhelming majority of PV companies deploy quality products and systems, those that do not, need to be brought up to the level of the rest of the PV industry, in order to avoid jeopardizing customer confidence in the quality and reliability of PV products and systems. The purpose of this Quality Management in Photovoltaics Training Manual is to help the PV firms install their own quality management system and meet established global quality standards. Achieving a benchmark global quality for PV components and systems will not happen overnight. Some very real barriers must be removed. However, good quality always cost less in the end. Companies that strive for quality can expect to be rewarded with greater profits.
Establishing a quality manufacturing process and maintaining a quality assurance system are sometimes viewed as expensive undertakings, especially for small or medium size companies. On the contrary, it has been proven that the presence of a quality manufacturing management system actually results in cost savings, even in the first year the quality management system is installed.
Other types of industries, facing similar quality assurance challenges have created solutions that the PV industry can study and adopt. Today, the ISO 9001:2000 standard is the globally accepted system for quality management of the manufacturing process, distributors, system assemblers and installers . This is a generic standard, used by many industries. Several PV module manufacturers presently meet the ISO 9001:2000 standard and are certified, but many do not. Of the latter, some simply may not know about the standard, while others may think that the ISO 9001:2000 implementation is too technical and/or expensive to be practical for small and medium-size companies.
The Global Approval Program for Photovoltaics (PV GAP) was created by the worldwide PV industry to establish a uniform approach to quality assurance. This Training Manual is part of that effort. PV GAP has developed this Manual to spell out in simple terms what is required by the ISO 9001:2000 standard and to help PV companies install a quality management system easily and inexpensively, without need for outside consultant assistance.
The Manual builds on an earlier Manual and training courses developed by PV GAP under a contract from the World Bank. That work focused on the existing standard at that time (ISO 9000). Since then, the ISO 9000 standard has been replaced by the ISO 9001:2000 standard. This Training Manual consequently explains the new ISO 9001:2000 and provides companies with the tools needed to comply fully, yet with an economy of effort, with all the ISO requirements.
Quality Assurance calls for a quality manufacturing process (e.g., ISO 9001:2000). It also requires that products be manufactured and tested according to a standard, and that the manufacturing process include continuous verification, auditing and improvement. This Training Manual describes the various elements of the Quality Management System. The Manual also introduces the PV Quality Mark and Seal and explains how these labels help customers distinguish high quality PV components and systems from those of poor or unknown quality. The PV Quality Mark and Seal also enhance the globally competitive position of PV manufacturers who are qualified and licensed to use these Labels.
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